Spring filled mattress or cushion



Sept. 18, 1934. w. B. FOSTER SPRING FILLED MATTRESS OR CUSHION FiledJuly 25, 1932 2 Sheets-Sheet l INVENTOR FIG.4

ATTORNEYS H W. B. FOSTER SPRING FILLED MATTRESS OR CUSHION 1932 2Sheets-Sheet 2 Filed July 25 FIG. 5

FIG.6

INVENTOR ATTORNEY S Fatented Sept. 18, 1934 SPRING FILLED MATTRESS R-CUSHION William. :3. Foster, Uflca, N. 'Y., assignor to Foster BrothersManufacturing Company,

Utlca, N. Y., a corporation or New York Application July 25, 1932,Serial No. 624,383 2 Claims. (0]. -380) This invention relates to aspring-filled mattress or cushion and to the process of making th same.The chief purpose of my present invention is to I provide aspring-filled mattress or cushion which is of novel and improvedconstruction and to show the process of manufacturing the same. Anotherpurpose is to provide an article of the class described which iseconomical and strong in construction and durable and efllcient m useand particularlywell adapted to maintain the boxing along the narrowsides of the mattress or cushion in a neat and permanent condition.

Another purpose is to provide a construction having positive butyielding means for maintaining the boxing of the cushion or mattress invertical position by securely anchoring the same to parts such as a padalong the narrow sides of the mattress or cushion which pad in turn inmypres ierred construction is positively connected as by stitches ofsewing to the spring-filling.

Further purposes of my present invention will appear from thespecification and claims herein.

Fig. 1 is a view partly in vertical section and v partly in sideelevation of part of an encased spring-filling that may be used in thisconstruction.

Fig. 2 is an isometric projection of a short length of a pad used inthis construction. Fig. 3 is a view partly in vertical section andpartly in side elevation of the spring-filling showing in verticalsection the pad placed upon and secured to the.

narrow sides or edges of the encased spring-filling. Fig. 4 is a viewsimilar to Figs. 1 and 3 after the top, bottom and edge layers offibrous filling have been added to the structure shown in Fig.- 3 andthe whole encased in the tick. Fig. 5 is a view similar to Fig. 4 of theparts therein shown, but

alter the tie tapes or similar members have been 46 inserted in thenarrow sides of the tick through the layer of fibrous filling adjacentthereto and into the outer fabric layer of the pad and after the rolledge stitching has been made. Fig. 6 is a. side elevation of part of aspring-filled mattress or cushion embodying this invention. Fig. 'l' isa horizontal sectional view on line 7--7 of Fig. 5. Fig. 8 is ahorizontal sectional view as on line 8-8 oi Fig. 5 but showing aspring-filling where a border rod is used. Fig. 9 is a sectional viewsimi- 59 lar to Fig. l, but showing a modified construction of myinvention where no fabric casing is placed directly about the springfilling and also where the pad overlaps the top and bottom of the edgesprings to a somewhat greater extent. Fig. 10 is a view of theconstruction shown in Fig. 9 mostly on line l0--10 01 Fig. 9. Fig. 11 isa vertical cross sectional view similar to Fig. 3 of a still furthermodified form of my invention where the pad is attached to the casing ofthe spring filling, but not directly to the spring filling. 30

Referring to the illustrations in a more detailed description, it willbe obvious that the springfilllng unit 10 consists of the proper numberof vertically arranged coiled springs 11 of general cylindrical shapeand secured together usually in 66 transverse and longitudinal rows byhaving the end coils 12 of the adjacent springs fastened together byclips or other tie members the form of which is'not material to thisinvention.

This unit 10 is enclosed in a complete fabric casing 13 commonly ofburlap and formed to en-- close the broad top and bottom surfaces of thespring unit and also the four narrow sides or edges of the spring unitas suggested in Fig. 1.

There is next placed entirely about the narrow sides or edges of encasedspring unit a long pad 14. This pad as clearly illustrated in Fig. 2 mayconveniently be formed of an outer fabric layer 15 of fairly substantialcloth and an inner fabric layer 16 which may be of less substantialcloth. Between these fabric layers there is placed .and secured aconsiderable layer l7 0! fibrous filling such as cotton, cotton feltingor the like with the fibrous filling held in place by the upper andlower seams of stitches 18 and 19 fastening the edges of the outer andinner iabric, layers 15 and 16 together and also by an intermediateseries ot stitches 20 preferably extending lengthwise oi the pad andgoing through not only the outer and inner fabric layers 15 and 16 butalso through all the intervening fibrous filling 17 and contracting thatfilling closely togetheralong the line of the stitches 20. This padmaybe conveniently made in lengths at least long enough to entirelyencircle a mattress or cushion or may be made of indefinite lengthsseveral times the perimeter of the ordinary mattress o1 cushion.

The pad 14 is then arranged along all four narrow sides or edges of theencased spring- :dlllng and the edges of the pad are turned over at thetop and bottom to some extent along the top and bottom surfaces of theencased springfilling so as to form that much more protection over thetop and bottom edges of the encased 6 spring-filling. In some of theillustrations 9. border wire 21 is shown at the outer edge of the topand bottom end coils 12 so as to maintain a definite straight edge forthe spring-filling and so as also to provide in that embodiment of my110 iii) wire not only opposite the springs, but in the spaces betweenthe springs. In constructions where for one reason or another it is notdesirable to use a border wire 21 the row of stitches 22 and 23 willenclose some of the fabric casing 13.

It will be seen that preferably the tie stitches 22 and 23 will not onlyfasten the pad 14 to the spring-filling but will also fasten the burlapor other fabric casing 13 to the spring-filling at the top and bottom ofeach edge spring. The parts so far assembled are shown in Fig. 3.

The next steps in the making of the construction are to place a toplayer 24 of fibrous filling over the top of the pad-bound spring unitand another similar fibrous layer 25 below the bottom of the unit and toplace about all four narrow sides of the unit outside the pad 14 a layer26 of fibrous filling. It will be noted that the fibrous filling layer26 does not need to be as thick as the top and bottom layers 24 and 25.Infact the total thickness of the pad 14 and the fibrous edge layer 26may be appreciably less than the height or thickness of the top andbottom layers 24 and 25.

The next step is to enclose the structure so far described in a tick 27consisting of a top 28 and bottom 29 of the full'length and width of themattress or cushion being made and a narrow side or edge portion 30 inwidth equalling the height of the mattress or cushion and preferablymade in a length long enough to go about the four narrow sides of themattress or cushion. Commonly this tick will be pre-made to the extentof being made up into an open-ended box form, that is with the top 28and bottom 29 sewed to the adjacent edges of the narrow side or edgepiece 30 along two long sides and one end of the mattress or cushion,but with one end not sewn into place butleft as an open flap. In thepreferred form of my construction this narrow side portion 30 isprovided before being assembled on a mattress with rows of eyelets 31..The eyelets of each row are arranged in pairs, that is with tworelatively close together and with the next pair spaced therefrom sayabout one-half to twothirds the diameter of the springs being used inthe spring filling. Preferably also as shown in Figs. 5 and 6 there willbe two rows of such spaced pairs of eyelets preferably with each row infrom the edge of the narrow side a little less than one-third the widthof the narrow side. These eyelets are for the purpose of strengtheningthe fabric of the tick when the tie tapes 32 are placed through thenarrow sides of the tick to the outer fabric layer 15 of the pad. Theeyelets may be formed in any convenient way such as by the use of aspecial button-hole machine which makes a ring of radially arrangedinter-connected stitches.

The assembling of the tick and the spring filling with its attached pad14 and the upper and lower layers 24 and 25 of fibrous filling and theouter edge layer of t .e fibrous filling 26 is most convenientlyperformed with the aid of a mattress-filling machine or device whichholds the layers of fibrous fillings in place about the spring fillingwhile the tick 2'7 is bodily drawn over the other parts or what is thesame while the said other parts are moved into the expanded but openended tick. The partly connected loose end of the tick is then connectedat the rest of its edges to the tick byseams of stitches.

The narrow sides 30 of the tick are then permanently but flexiblyconnected to the pad 14 and particularly to the outer fabric layer 15 ofthe pad by loops of tie tapes or string 32. These tie tapes or strings32 are sewed or led into the Y structure preferably with the aid of acircular mattress-making needle so that as shown particularly in Figs. 7and 8 the tape goes inwardly.

through one eyelet and through the narrow side layer 30 of the tick andthen in a slanting or curved direction generally horizontally throughthe outer side layer of V fibrous filling 26 and into and through the,outer and, relatively strong fabric layer 15 of the pad 14 and thenoutwardly again through this'fabric layer 15 and again through the outerfibrous filling 26 toward the nearest eyelets of an adjacent pair ofeyelets in the same row. After the tape is drawn up a proper amount anew stitch or loop is taken in a similar way through the other eyelet ofthe pair where the tape came out and through the parts already mentionedand out again into the first eyelet of the next or second succeedingpair of eyelets in a row. These tie strings 32 will preferably befastened from time to time and particularly will have their meeting endstied to each other when a series of loops or stitches is completed aboutthe mattress.

It will now be seen that the intermediate portions of the side of themattress or cushion are thoroughly and permanently anchored to thespring filling by means of these tie tapes fastening the outer andnarrow sides of the ticking to the outer layer of the stuffed pad 14which pad in turn is fastened at its top and bottom at frequentintervals to the spring filling. The appearance is more or less thatshown in Fig.'5 and the parts will be retained in this position afterlong and hard usage by reason of the positive connection of the pad tothe spring filling and the yielding but positive connection between thepad and the narrow sides of the tick. The construction so far describedis entirely usable and is preferred in many cases. In Fig. 5, however, Ihave shown the manner in which the usual roll edge may be produced inthis construction by the use of stitches 33 extending diagonally on theslant from the narrow side of the tick to the upper side of the top 28of the tick in one series and in another series to the outer surface ofthe bottom 29 of the tick. By drawing these strings or stitches in tothe v proper extent the engaged portions of the ticking are drawn in andthe desired bulged or roll edge effect is produced without interferencewith 1% is made preferably wider than the height of the spring fillingso that the two edges of the pad over-lap the top and bottom of thespring filling to a much greater extent than is shown in igs. 3, 4 and5. In fact, in this modification the pad is made wide enough so that theside extremities of the pad will come alittle inside of the center ofthe end coils of the .edge springs! of the.

spring-filling; This allows each set or group of stitches or tie threads35 fastening the pad to the spring filling to go about the end coils'oitwo adjacent edge springs where the said end coils closely approach ortouch each other; It will be seen that stitches or tie threads so placedcannot slide around on the end coils and so the side edges ofcombination of a filling of vertically-arranged the narrow sides andover the adjacent edges of the spring filling and sewed thereto near theupper and loweruedges of the pad, layers of fibrous filling about thetop and bottom of the spring filling and a vertical layer oppositethesaid pad, a tick enclosing said parts and tie tapes in loops passingirom the outside of the tick inwardly only to, and engaging the insideof the outer fabric layer of the pad.

2. In a spring-filled mattress'or cushion, the combination of a fillingof vertically-arranged coiled springs, a pre-made pad of inner and outerlayers of fabric enclosing a fibrous filling, and at least as wide asthe spring filling and extending along the narrow sides of the springfilling and sewed thereto near the upper and lower edges of the pad,layers of fibrous filling about the top and bottom of the spring fillingand a vertical layer opposite the said pad, a tick enclosing said partsand tie tapes in loops passing from the outside of the tick inwardlyonly to, and engaging the inside of the outer fabric layer of the pad.

- B. FOSTER.

